Process for preparing cinacalcet hydrochloride

ABSTRACT

A process for preparing N-[(1R)-1-(1-naphthyl)ethyl]-3-[3-(trifluoromethyl)-phenyl]propan-1-amine hydrochloride salt of formula (I) 
     
       
         
         
             
             
         
       
     
     i.e. Cinacalcet hydrochloride and its intermediates of formulae (VII) and (VIII) 
     
       
         
         
             
             
         
       
     
     wherein Z is chloride or another pharmaceutically acceptable anionic counterion.

The invention relates to a process for preparing the active productingredient Cinacalcet hydrochloride (CNC.HCl), namelyN-[(1R)-1-(1-naphthyl)ethyl]-3-[3-(trifluoromethyl)phenyl]propan-1-aminehydrochloride of formula (I)

CNC.HCl, marketed as MIMPARA™ in the European Union, is a calcimimeticagent that decreases the secretion of parathyroid hormone by activatingcalcium receptors.

MIMPARA™ is approved for the treatment of secondary hyperparathyroidism(SHPT) in patients with chronic kidney disease receiving dialysis andfor the treatment of primary hyperparathyroidism (PHPT) in patients forwhom parathyroidectomy is not clinically appropriate or contraindicated.

U.S. Pat. No. 6,011,068 discloses a class of arylalkylamines comprisinggenerically Cinacalcet (CNC) and salts thereof. U.S. Pat. No. 6,211,244describes specifically Cinacalcet or a pharmaceutically acceptable saltor complex thereof as the compound 22J, but it does not provide anyspecific examples for the preparation of Cinacalcet and/or Cinacalcethydrochloride.

Most prior art processes for preparing the hydrochloride salt ofCinacalcet typically comprise: providing a solution of Cinacalcet in asolvent; treating said solution with an amount of hydrochloric acidsufficient to convert Cinacalcet to its hydrochloride salt;precipitating said hydrochloride salt and recovering said salt.

For example, U.S. Pat. No. 7,247,751 generically describes a method ofpreparing Cinacalcet hydrochloride crystalline form I, which comprisesproviding a solution of Cinacalcet base in a solvent in which Cinacalcethydrochloride has a low solubility; acidifying the solution withhydrochloric acid to obtain a reaction mixture; maintaining the reactionmixture to obtain a precipitate; and recovering the precipitatedCinacalcet hydrochloride crystalline Form I. Preferably, the solvent isselected from the group consisting of acetone, ethanol, isopropylalcohol, and methanol. The preparation of Cinacalcet hydrochloridecrystalline form I from Cinacalcet is specifically described in Example5 of U.S. Pat. No. 7,247,751, wherein a solution of Cinacalcet wasformed by dissolving Cinacalcet base in absolute ethanol, hydrochloricacid was added drop-wise to the solution and the resulting mixture wasstirred at ambient temperature, producing a precipitate. The product wasisolated by filtration and dried in a vacuum, yielding Cinacalcethydrochloride crystalline form I. Example 9 of WO 2008/058235 disclosesthe preparation of Cinacalcet hydrochloride starting fromN-[(1R)-1-(1-napthyl)ethyl]-3-(3-trifluoromethyl)phenyl]propanamide,without isolating Cinacalcet free base.

WO 2008/058235 provides a process for making Cinacalcet hydrochloridefrom Cinacalcet that includes the steps of: providing a solution ofCinacalcet in an alcohol or alkyl acetate; treating the solution of thefree base with an hydrochloric acid to convert the free base to thehydrochloride salt; adding an anti-solvent to solution containing thehydrochloride salt to precipitate it in the form of a solid; andisolating the precipitated solid to obtain the Cinacalcet hydrochloride.WO 2008/058235 also describes a process for making Cinacalcethydrochloride by providing a solution of an acid addition salt ofCinacalcet other than Cinacalcet hydrochloride, treating said solutionwith an amount of hydrochloric acid sufficient to convert the acidaddition salt to said hydrochloride salt; and isolating said cinacalcethydrochloride.

U.S. Pat. No. 7,393,967 discloses a process for preparing Cinacalcethydrochloride via coupling of 3-bromotrifluorotoluene with(R)—N-(1-(naphthalen-1-yl)ethyl)prop-2-en-1-amine in the presence of acatalyst and at least one base to obtain(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine(Example 1, Step 1), reducing the unsaturated Cinacalcet to obtainCinacalcet (example 1, Step 2), and converting Cinacalcet to Cinacalcethydrochloride (Example 2 or Example 3) as depicted in the followingScheme 1:

The present invention provides, in a first aspect, a novel and efficientmethod that leads to a Cinacalcet salt, especially the hydrochloride,which is convenient for the industrial scale and provides the desiredproduct in good yields. In particular, the inventors found thatCinacalcet hydrochloride can be advantageously obtained with a process,which does not contemplate the isolation of Cinacalcet free base.

Accordingly, it is an object of the present invention to provide amethod for preparing Cinacalcet hydrochloride of formula (I)

which comprises the steps of:

-   e) reducing a compound of formula (VII)

-   -   wherein Z is chloride or another pharmaceutically acceptable        anionic counterion, to obtain a compound of formula (Ia)

-   -   wherein Z is as defined above and, when in a compound of formula        (Ia) Z is a pharmaceutically acceptable anionic counterion        different from chloride,

-   f) converting said compound of formula (Ia) to Cinacalcet    hydrochloride of formula (I).

A “pharmaceutically acceptable anionic counterion” Z refers to anegatively charged molecule or atom that is balanced by the positivelycharged protonated Cinacalcet. A pharmaceutically acceptable anioniccounterion may be organic or inorganic. For example, representativepharmaceutically acceptable anionic counterions include chloride,bromide, bisulfate (hydrogen sulfate), methanesulfonate,p-toluenesulfonate, phosphate, hydrogenphosphate, oxalate, formate,acetate, citrate, tartrate, succinate, maleate and malonate. Chloride,bisulfate, p-toluenesulfonate, tartrate and succinate are preferred;chloride and bisulfate are more preferred.

As an example, the compound of formula (VII) wherein Z is chloride isthe compound of formula (VIIa),

the compound of formula (VII) wherein Z is bisulfate is the compound offormula (VIIb),

the compound of formula (VII) wherein Z is tartrate is the compound offormula (VIIc),

the compound of formula (VII) wherein Z is succinate is the compound offormula (VIId),

and the compound of formula (VII) wherein Z is p-toluenesulfonate is thecompound of formula (VIIe)

In a preferred aspect, the present invention is directed to a method forpreparing Cinacalcet hydrochloride of formula (I), which comprises thestep of reducing the compound of formula (VIIa) as defined above.

In another aspect, the method according to the present invention furthercomprises obtaining the compound of formula (VIIa) as defined above, bya process which comprises the step of:

-   g) converting a compound of formula (VII) wherein Z is a    pharmaceutically acceptable anionic counterion different from    chloride.

In a further preferred aspect, the method according to the presentinvention further comprises obtaining the compound of formula (VIIa) asdefined above, by a process which comprises the step of:

g) converting a compound of formula (VIIb) as defined above.

The reduction according to the above step e) can be carried out startingfrom a compound of formula (VII), particularly the compound of formula(VIIa), by catalytic hydrogenation, i.e. with molecular hydrogen in thepresence of a catalyst. The catalytic hydrogenation may be performed byany method known to a person skilled in the art. For example, a compoundof formula (VII), particularly the compound of formula (VIIa), may bedissolved in a in a suitable solvent and exposed to H₂ pressure, in thepresence of a catalyst such as, for example, Pd/C, PtO₂ (Adam'scatalysts), Raney nickel or PdCl₂. When the catalyst is selected fromPd/C, PtO₂ or PdCl₂, the H₂ pressure is chosen in the range of from 0.5to 5 atm, while when the catalyst is Raney nickel, the H₂ pressure ischosen in a higher range from 4 to 70 atm. The suitable solvent can beselected from the group consisting of a C₂-C₅ nitrile such as, forexample, acetonitrile; a linear or branched C₁-C₄ alcohol such as, forexample, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl ortert-butyl alcohol; a linear or branched C₃-C₉ ketone such as, forexample, methylethyl or methylisobutyl ketone; a linear or branchedC₃-C₇ ester such as, for example, ethyl, iso-propyl or n-butyl acetate;toluene and mixtures thereof. Preferably, the solvent can be selectedfrom the group consisting of methanol, ethanol, isopropanol, ethylacetate and mixtures thereof, more preferably the solvent is methanol.Typically, the hydrogenation is carried out over a period of about 1hour to 96 hours. Reaction temperature may range from 0° to 50° C.,preferably from 10° to 30° C., more preferably at 20° C.

The conversion of a compound of formula (Ia) into Cinacalcethydrochloride of formula (I) according to the above step f), and theconversion of a compound of a formula (VII) where Z is an anioniccounterion different from chloride into a compound of formula (VIIa)according to step g), can be carried out dissolving a compound offormula (Ia) as defined above or, respectively, a compound (VII) asdefined above, in a solvent selected from water; a linear or branchedC₁-C₄ alcohol such as, for example, methyl, ethyl, n-propyl, iso-propyl,n-butyl, sec-butyl or tert-butyl alcohol; a linear or branched C₄-C₈ester such as, for example, ethyl acetate, isopropyl acetate or n-butylacetate; or mixtures thereof, at a temperature ranging from roomtemperature to the boiling point of the selected solvent, or mixture ofsolvents, and treating said compounds with aqueous hydrochloric acid. Amoderately high excess of hydrochloric acid (2-10 equiv.) has to be usedwhen the acid HZ is a stronger acid than hydrochloric acid.

The conversion of a compound of formula (VII) where Z is an anioniccounterion different from chloride into a compound of formula (VIIa)according to step g), can be alternatively carried out suspending acompound of formula (VII) as defined above in a solvent selected fromtoluene; a linear or branched C₄-C₈ ether such as, for example, methyltert-butyl ether, diisopropyl ether or di-n-butyl ether; a linear orbranched C₄-C₈ ester such as, for example, ethyl acetate, isopropylacetate or n-butyl acetate; or mixtures thereof, and treating saidcompound with an aqueous base, such as for example sodium hydroxide,sodium or potassium carbonate, sodium or potassium hydrogen carbonate,sodium or potassium phosphate, extracting the so obtained unsaturatedCinacalcet free base (CNC-ene free base) in the organic layer andprecipitating the compound of formula (VIIa) from the organic solventupon treatment with aqueous hydrochloric acid.

A compound of formula (VII) can be obtained converting(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine(CNC-ene free base) by any method known to a person skilled in the art.CNC-ene free base can be prepared, for example, as depicted in the U.S.Pat. No. 7,393,967, Example 1, Step 1, or following the teachings of theZaCh System co-pending European patent application No. 08167762.7.

Alternatively, a compound of formula (VII), wherein Z is apharmaceutically acceptable anionic counterion different from chloride,can be obtained with a novel method which comprises the step of:

j) eliminating sulfuric acid from the compound of formula (VIII)

-   -   wherein the wavy line represents a bond connected to carbon        having R or S configuration, with a strong acid, neutralizing        and acidifying with the proper acid HZ, wherein Z is a        pharmaceutically acceptable anionic counterion different from        chloride.

In a preferred aspect, the compound of formula (VIIb) as defined abovecan be obtained by a method which comprises the step of:

-   j) eliminating sulfuric acid from the compound of formula (VIII) as    defined above with a strong acid, neutralizing and acidifying with    H₂SO₄.

It is therefore another object of the present invention to provide amethod for preparing Cinacalcet hydrochloride of formula (I) as definedabove, which further comprises preparing a compound of formula (VII)wherein Z is a pharmaceutically acceptable anionic counterion differentfrom chloride, with a process which comprises the above step j).

The elimination of sulfuric acid according to the above step j) can becarried out by reacting the compound of formula (VIII) with a strongacid such as, for example, sulfuric or phosphoric acid, preferablyconcentrated sulfuric acid, with or without a solvent selected from highboiling toluene, n-butyl acetate and n-butyl ether, preferably n-butylacetate, and at a temperature ranging from room temperature to therefluxing temperature of the selected solvent, preferably 115° C. Oncethe reaction has gone to completion, a compound (VII) wherein Z is apharmaceutically acceptable anionic counterion different from chloride,can be obtained by any work up method known to a person skilled in theart. For example, a compound of formula (VII) as defined above can beisolated by neutralizing the acidic reaction mixture with an aqueousbase, preferably sodium hydroxide, extracting the compound(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine(CNC-ene free base) in organic phase, preferably in n-butyl acetate,acidifying said organic phase with the proper acid HZ, wherein Z is apharmaceutically acceptable anionic counterion different from chloride,preferably bisulfate, and precipitating the corresponding compound offormula (VII).

It is a further object of the present invention the Cinacalcetintermediate of formula (VIII) as defined above.

The compound of formula (VIII) as defined above can be obtained with anovel method which comprises the step of:

k) reducing the compound of formula (V)

to the corresponding benzylic alcohol of formula (Va)

-   -   in the presence of a reducing agent or by mean of a catalytic        hydrogenation process, and        l) converting the compound of formula (Va) into the sulfate        ester of formula (VIII).

In the formula (Va), [ ] means that the compound of formula (Va) can beisolated or not from the reaction mixture.

The reduction of the compound of formula (V) according to the above stepk) can be carried out with suitable reducing agents including sodiumborohydride; lithium borohydride; diisobutyl aluminium hydride; and1,1,3,3-tetramethyldisiloxane in combination with a Lewis acid. Suitablereduction catalysts, which can be used with gaseous hydrogen, includePd/C, PtO₂ (Adam's catalysts), Raney nickel and PdCl₂. The reaction canbe carried out in a solvent selected from, for example, water; a linearor branched C₁-C₄ alcohol such as, for example, methyl, ethyl, n-propyl,iso-propyl, n-butyl or sec-butyl alcohol; a linear or branched C₄-C₈ether such as 1,2-dimethoxyethane, 2-methoxyethyl ether, diisopropylether, di-n-butyl ether, methyl tert-butyl ether, tetrahydrofuran or1,4-dioxane; or a mixture thereof, depending on the reducing agent; at atemperature ranging between −10° to 40° C., over a period of about 0.5to 10 hours. When the catalyst Pd/C, PtO₂ or PdCl₂ is used, the H₂pressure is typically 1 atm. When Raney nickel is used, the H₂ pressureis moderately high (—1000 psi). Typically, the hydrogenation is carriedout over a period of about 5 to about 24 hours. When the reduction iscarried out upon catalytic transfer hydrogenation (CTH) conditions,suitable hydrogen-bearing feed materials such as, for example, formicacid, ammonium formate or sodium formate, preferably ammonium formate orsodium formate are employed. In order to activate the hydrogen-bearingmaterial as hydrogen donor, a catalyst as defined above is employed: thecatalyst promotes the hydrogen transfer from hydrogen-bearing feedmaterial to the substrate. CTH may be performed by any method known to aperson skilled in the art. In particular, when CTH techniques are usedin the reaction under step k), the compound of formula (V) is dissolvedin a solvent selected from for example, toluene, acetic acid and a C₁-C₅alcohol as defined above, preferably ethyl alcohol, in the presence offormic acid, ammonium formate or sodium formate, preferably ammoniumformate or sodium formate, at refluxing temperature of the selectedsolvent, over a period of about 5 to 48 hours. In a most preferredembodiment, sodium borohydride in methanol at a temperature ranging from−10° C. to 10° C. is used.

Once the intermediate benzylic alcohol of formula (Va) is formed, eitherit is isolated or not, it can be converted into the sulfate ester offormula (VIII) according to the above step 1) by treatment with sulfuricacid and acetic anhydride, in a solvent selected from acetonitrile, aC₄-C₈ ether as defined above, a linear or branched C₄-C₆ ester, such as,ethyl, iso-propyl, n-butyl acetate, or a mixture thereof, at atemperature ranging from 0°-50° C., most preferably at 25° C.

It is therefore another object of the present invention to provide amethod for preparing Cinacalcet hydrochloride of formula (I) as definedabove, which further comprises preparing the compound of formula (VIII),with a process which comprises the above steps k) and l), with orwithout the isolation of the intermediate compound of formula (Va).

For clarity's sake, the above processes may be illustrated by thefollowing Scheme 2:

In a particular aspect, the present invention provides a method forpreparing Cinacalcet hydrochloride of formula (I)

which comprises the steps ofk) reducing the compound of formula (V)

to the corresponding benzylic alcohol of formula (Va)

-   -   wherein [ ] means that the compound of formula (Va) can be        isolated or not from the reaction mixture, in the presence of a        reducing agent or by mean of a catalytic hydrogenation process,        l) converting the compound of formula (Va) into the sulphate        ester of formula (VIII)

-   -   wherein the wavy line represents a bond connected to carbon        having R or S configuration,

-   j) eliminating sulfuric acid from the compound of formula (VIII)    with a strong acid, neutralizing and acidifying with H₂SO₄ to give    the compound of formula (VIIb)

g) converting the compound (VIIb) into the compound (VIIa) and

e) reducing the compound (VIIa) to obtain Cinacalcet hydrochloride offormula (I).

The compound of formula (V) as defined above can be prepared accordingto the methods described in ZaCh System's co-pending European patentapplication No. 08167762.7, which comprises the step of:

a) reacting 3-(trifluoromethyl)acetophenone of formula (II)

with (R)-(1-naphthyl)ethylamine of formula (III), optionally in thehydrochloride form,

in the presence of formaldehyde and hydrochloric acid to give thecompound of formula (V)

In a preferred aspect of the present invention, the reaction under theabove step a) is carried out with (R)-(1-naphthyl)ethylaminehydrochloride salt.

It is therefore a further object of the present invention to provide amethod for preparing Cinacalcet hydrochloride of formula (I) as definedabove, which further comprises preparing the compound of formula (V),with a process which comprises the above step a).

According to ZaCh System co-pending European patent application No.08167762.7, the compound of formula (V) can also be prepared with aprocess which comprises the steps of:

b) reacting the compound of formula (II) as defined above(i) with a compound of formula

HNR₁R₂,

-   -   wherein R₁ and R₂ represent, independently, hydrogen or C₁-C₅        alkyl, provided that when one of R₁ and is hydrogen, the other        is not hydrogen; or    -   wherein R₁ and R₂ together form a C₄-C₇ alkyl bridge, so that        with the inclusion of the nitrogen atom to which they are linked        a heterocycle is formed, wherein one —CH₂— group of the C₄-C₇        alkyl bridge, can be replaced by —O—, in the presence of        formaldehyde; or        (ii) with a N-methyl-N-methylenemethanaminium halide of formula

-   -   wherein Hal is a halogen atom,        to obtain the compound of formula (IV)

-   -   wherein R₁ and R₂ are as defined above;

-   c) alkylating the compound of formula (IV) with an alkylating agent    selected from the group of compounds of formula:    -   R₃—X, CO(OR₃)₂, SO₂(OR₃)₂, PO(OR₃)₃, CH₃PO(OR₃)₂ and        (4-NO₂C₆H₄O)PO(OR₃)₂, wherein R₃ is C₁-C₄ alkyl and X is I, Br,        OSO₂CF₃ or OSO₂F, to obtain a compound of formula (IVa)

-   -   wherein Y═X as defined above, R₃OCO₂, R₃OSO₃, (R₃O)₂PO₂,        CH₃PO₂OR₃, or (4-NO₂—C₆H₄O)PO₂OR₃;

-   d) coupling a compound of formula (IVa) with    (R)-(1-naphthyl)ethylamine of formula (III) to give the compound of    formula (V)

It is therefore a still further object of the present invention toprovide a method for preparing Cinacalcet hydrochloride of formula (I)as defined above, which further comprises preparing the compound offormula (V), with a process which comprises the above steps b) to d).

For clarity's sake, the above processes for preparing the compound offormula (V) may be illustrated by the following Scheme 3 (correspondingto Scheme 7 of the ZaCh System's co-pending European patent applicationNo. 08167762.7):

The preparation of the compound of formula (V) according to the abovestep a) or steps b) to d) can be carried out under the reactionconditions described in ZaCh System's co-pending European patentapplication No. 08167762.7.

The present invention is exemplified by the following examples, whichare provided for illustration only and should not be construed to limitthe scope of the invention.

EXAMPLE 1 Synthesis of(R)-3-(1-(naphthalen-1-yl)ethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-onehydrochloride salt (V) Method A

(R)-(1-naphthyl)ethylamine hydrochloride (III) (100.0 g),paraformaldehyde (15.9 g), 3-(trifluoromethyl)acetophenone (II) (135.7g), 30% w/w aqueous hydrochloric acid (5.6 g), ethanol (150.0 g) andwater (10.0 g) were charged into the reactor and stirred at reflux for14 hrs, until satisfactory conversion was observed via HPLC. Then water(300.0 g) and toluene (305.0 g) were added and the mixture was stirredat 25° C. The organic and aqueous layers were separated and additionalwater (200.0 g) was charged over the organic phase in order to favourthe precipitation. The title compound (95.6 g) was isolated uponfiltration at room temperature, washing with water and methyl tert-butylether and exsiccation at 50° C.

Method B

(R)-(1-naphthyl)ethylamine hydrochloride (III) (1.5 g), paraformaldehyde(0.3 g), 3-(trifluoromethyl)acetophenone (II) (1.8 g), 30% w/w aqueoushydrochloric acid (0.1 g), ethanol (4.5 g) and water (1.5 g) werecharged into the reactor under stirring and reacted for 5 minutes undermicrowave irradiation (max 250 W), until satisfactory conversion wasobserved via HPLC. Then water (10.0 g) and toluene (3.0 g) were addedand the resulting suspension was stirred at 25° C. The title compound(1.6 g) was isolated upon filtration at room temperature, washing withwater and methyl 2-propanol and exsiccation at 50° C.

Method C

(R)-(1-naphthyl)ethylamine (III) (82.4 g), paraformaldehyde (15.9 g),3-(trifluoromethyl)acetophenone (II) (135.7 g), 30% w/w aqueoushydrochloric acid (52.9 g), ethanol (150.0 g) and water (10.0 g) werecharged into the reactor and stirred at reflux for 14 hrs, untilsatisfactory conversion was observed via HPLC. Then water (300.0 g) andtoluene (305.0 g) were added and the mixture was stirred at 25° C. Theorganic and aqueous layers were separated and additional water (200.0 g)was charged over the organic phase in order to favour the precipitation.The title compound (95.6 g) was isolated upon filtration at roomtemperature, washing with water and methyl tert-butyl ether andexsiccation at 50° C.

NMR of(R)-3-(1-(naphthalen-1-yl)ethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-one hydrochloride salt (V)

¹H NMR (400 MHz, DMSO-d₆), δ (ppm, TMS): 10.00 (1H, br s; —NH₂ ⁻—), 9.24(1H, br s; —NH₂ ⁻—), 8.31 (1H, d, J=8.4; ArH), 8.23 (1H, d, J=8.0 Hz;ArH), 8.16 (1H, br s; ArH), 8.08-7.96 (4H, m; ArH), 7.82 (1H, t, J=8.0Hz; ArH), 7.69-7.58 (3H, m; ArH), 5.47-5.36 (1H, m; —CH(CH₃)—),3.70-3.54 (2H, m; —CH₂—), 3.41-3.26 (2H, m; —CH₂—), 1.72 (3H, m, J=6.4Hz; —CH(CH₃)—).

EXAMPLE 2 Synthesis of3-(dimethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-onehydrochloride (IV)

A mixture of 1-(3-(trifluoromethyl)phenyl)ethanone (25.0 g) (II),dimethylamine hydrochloride (13.0 g), paraformaldehyde (4.8 g), 31% w/waqueous hydrochloric acid (0.5 mL) in ethanol (70 mL) was stirred atreflux temperature for 24 hrs, then cooled down and the solvent flushedwith toluene (50 mL). The precipitated pale yellow solid was thenfiltrated, washed with toluene and dried to give the title compound (IV)(28.0 g).

EXAMPLE 3 Synthesis of3-(dimethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-onehydrochloride (IV)

A mixture of 1-(3-(trifluoromethyl)phenyl)ethanone (5.0 g) (II),N-methyl-N-methylenemethanaminium iodide (5.4 g), 31% w/w aqueoushydrochloric acid (0.1 mL) in ethanol (7 mL) was stirred at refluxtemperature for 24 hrs, then cooled down and the solvent flushed withtoluene (50 mL). The precipitated pale yellow solid was then filtrated,washed with toluene and dried to give the title compound (IV) (7.1 g).

EXAMPLE 4 Synthesis ofN,N,N-trimethyl-3-oxo-3-(3-(trifluoromethyl)phenyl)propan-1-ammoniumiodide (IVa)

A vigorously stirred biphasic solution of3-(dimethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-one (IV) (15.0g) in a 1:1 water/toluene mixture (50 mL) was added over 1 hr at r.t.with 30% w/w aqueous sodium hydroxide until pH 14. The organic layer wasthen separated, dried with anhydrous Na₂SO₄ and filtered. The motherliquor was then charged in a reactor and added, under strong agitation,with methyliodide (22.6 g) in 30 min. The mixture was then kept at r.t.for 18 hrs to yield a yellow solid of the methylated Mannich base iodidesalt (18.0 g), compound (IVa), that was filtered, dried and used in thefollowing synthetic step without further purification.

EXAMPLE 5 Synthesis of(R)-3-(1-(naphthalen-1-yl)ethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-onehydrochloride salt (V)

A vigorously stirred suspension of the methylated Mannich base iodidesalt, compound (IVa) (20.5 g), (R)-(1-naphthyl)ethylamine (11.0 g) andpotassium carbonate (14.7 g) in acetonitrile (50 mL) was kept atrefluxing temperature for 8 hrs, then cooled down to r.t., added withwater (20 mL) and extracted twice with ethyl acetate (25 mL). Thecombined organic phases were then dried and concentrated to give thecrude title compound (V) (20.8 g) as yellow oil. Further purificationcould be achieved upon conversion of the compound (V) into itshydrochloride salt and recrystallization from MTBE.

EXAMPLE 6 Synthesis of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)-phenyl)prop-2-en-1-amine(CNC-ene free base)

The diastereoisomeric mixture of (R) and(S)-3-((R)-1-(naphtalen-1-yl)ethylamino-1-(3-(trifluoromethyl)phenyl)propan-1-ol(obtained following the teachings of Example 7 of ZaCh System'sco-pending European patent application No. 08167762.7) was charged intothe reactor as a toluene solution (33.7 g). Acetic acid (76.9 g) andconcentrated sulphuric acid (96% w/w; 49.0 g) were then added slowly at25° C., the reaction mixture was heated at 110° C. for 1 hr, then cooleddown to 5° C. The mass was diluted by addition of toluene (85.0 g) and,dropwise, water (50.0 g), then stirred at 25° C. for few minutes. Theorganic and aqueous phases were separated and the toluene layer wascooled to 5° C. and neutralized by addition of aqueous ammonia (28% w/w;40.0 g) up to pH 10. Once room temperature was reached, water (30.0 g)was added in order to solubilise salts, the phases were separated andthe solvent was removed form the organic layer via reduced pressuredistillation. The crude title compound was obtained as a pale yellow oil(17.7 g).

NMR of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine:

¹H NMR (400 MHz, CDCl₃), δ (ppm, TMS): 8.21-8.17 (1H, m; ArH), 7.92-7.86(1H, m; ArH), 7.78 (1H, d, J=8.0 Hz; ArH), 7.72 (1H, d, J=7.2 Hz; ArH),7.58-7.45 (6H, m; ArH), 7.43-7.37 (1H, m; ArH), 6.48 (1H, d, J=16.0 Hz;—ArCH═CHCH₂—), 6.39 (1H, dt, J=6.0, 6.0 Hz; —ArCH═CHCH₂—), 4.76 (1H, q,J=6.6 Hz; —CH(CH₃)—) 3.46-3.33 (2H, m; —CH₂—), 1.57 (3H, d, J=6.6;—CH(CH₃)—).

EXAMPLE 7 Synthesis of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)-phenyl)prop-2-en-1-aminehydrochloride salt (VIIa)

(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine(CNC-ene free base) (4.3 g, 12.122 mmol) is diluted with MTBE (50 ml)and added with 1.20 equiv. of 31% w/w aqueous hydrochloric acid. Excesswater is removed by azeotropic distillation. The organic phase is thenconcentrated up to 60% volume and the so formed precipitate is isolatedupon cooling down to 0° C. and filtering. Vacuum drying affords 4.6 g ofa white powder (VIIa; 11.739 mmol, 96.8% yield).

EXAMPLE 8 Synthesis of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amineHZ salts (VIIc) (VIId) (VIIe)

(VIIc)=(VII) wherein Z=tartrate;(VIId)=(VII) wherein Z=succinate;(VIIe)=(VII) wherein Z=p-toluenesulfonate

(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amine(CNC-ene free base) (4.3 g, 12.122 mmol) is diluted with MTBE (50 ml)and added with 1.05 equiv. of the acid HZ (where HZ: (c)=meso-tartaricacid, (d)=succinic acid, and (e)=p-toluensulfonic acid). Filtration ofthe so formed precipitate and vacuum drying affords the corresponding(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminesalts (VIIc), (VIId) or (VIIe), with yields ranging from (VIIc) 27.6%(white powder), to (VIId) 69.7% (white powder) and (VIIe) 94.5% (whitepowder).

EXAMPLE 9

Conversion of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amineHZ salt (VIIe) into(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa)

(VIIe)=(VII) wherein Z=p-toluenesulfonate

(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminep-toluenesulfonate (VIId) is free-based by addition of 30% w/w aqueousNaOH in a MTBE/water mixture at 25° C. up to pH 12 of the aqueous layer.The organic layer is then separated and acidified with 31% w/w aq. HCl(1.2 equiv.) up to pH 1 in the aqueous layer. The aqueous layer isseparated and residual water is stripped out of the organic phase byazeotropic distillation. Once water is completely removed the organicsolvent is distilled off (T=54°-55° C., P=900 mbar) until a 40%reduction of the total volume is achieved. The mixture is then cooleddown to 0° C. and filtered.(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa) is obtained as a white powder, with isolatedyields of 87.1%.

EXAMPLE 10 Synthesis of (R) and(S)-3-(R)-1-(naphthalen-1-yl)ethylammonio)-1-(3-(trifluoromethyl)phenyl)propylsulfate (VIII)

(R)-3-(1-(naphthalen-1-yl)ethylamino)-1-(3-(trifluoromethyl)phenyl)propan-1-onehydrochloride salt (V) (150.0 g, 365.934 mmol) is suspended in coldmethanol (570 ml) at −5°-0° C. and a solution of NaBH₄ (6.3 g, 166.534mmol, 0.45 equiv.), 30% aq. NaOH (53.8 g, 403.500 mmol, 1.1 equiv.) inwater (45 ml) is slowly added over 30 minutes. Once the reaction iscomplete (IPC via HPLC) acetic acid (55.0 g, 913.903 mmol, 2.5 equiv.)is charged slowly, keeping the internal temperature below 5° C.,followed by water (415 ml). The reaction mixture is then heated up to50° C. and the solvent is distilled off under reduced pressure to halfvolume. After that, isopropyl ether (450 ml) is charged, the mixture isstirred and, once layered, the lower phase is separated. The organicphase is washed with water (75 ml), then MTBE (400 ml) is added andwashed again with water (3×75 ml). Thus, volatile solvents are flushedwith isopropyl ether and residual water removed azeotropically.Acetonitrile (300 ml) is added at 10° C. and concentrated sulphuric acid(35.5 g, 347.507 mmol) is charged slowly, followed by acetic anhydride(71.0 g, 695.275 mmol) at 20°-25° C. The reaction mixture is stirred at20°-25° C. for about 1 hour, until complete conversion is observed viaHPLC, then cooled down to 0° C. The resulting precipitate is isolated byfiltration and washed with isopropyl ether (3×65 ml) and dried undervacuum at 55° C. The title compound (VIII) (152.9 g, 302.314 mmol) isobtained in 82.6% yield.

EXAMPLE 11 Synthesis of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-amineHZ salt (VIIb)

(VIIb)=(VII) wherein Z=bisulfate

A 500 ml reactor is loaded with (R) and(S)-3-((R)-1-(naphthalen-1-yl)ethylammonio)-1-(3-(trifluoromethyl)phenyl)propylsulfate (VIII) (55.0 g, 121.287 mmol) and n-butyl acetate (250 ml), and96% H₂SO₄ (37.1 g, 363.169 mmol, 3.0 equiv.) is added dropwise at roomtemperature. The reaction mixture is heated up to 115° C. and stirredfor 15 hours, then cooled down to 15° C. The reaction mixture is washedwith water (2×110 ml), 6% w/w aq. NaOH (139.2 g) and 8% w/w aq. NaHCO₃(110.0 g). The organic solution is then treated with charcoal andfiltered, washed with water (2×55 ml) and added with n-butyl acetate upto 400 ml total volume. The solvent is then distilled off up to halfvolume. The organic solution is added with n-butyl acetate (170 ml) andacidified with 96% w/w H₂SO₄ (11.2 g, 109.636 mmol). The resultingsuspension is heated up to 90° C. and stirred until a clear solution isobtained (1 hour). The solution is cooled down to 65° C. and maintaineduntil precipitation is observed, then cooled to 0° C. over 30 mins. Thesolid is filtered, washed with cold n-butyl acetate and dried at 50° C.under vacuum. The title compound (VIIb) (37.1 g, 81.814 mmol, 67.5%yield) is obtained as a white powder.

EXAMPLE 12

Conversion of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminebisulfate salt (VIIb) into(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa)

Method A

(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminebisulfate salt (VIIb) (55.1 g, 121.466 mmol) is free-based by additionof 30% w/w aqueous NaOH (34.8 g, 261.0 mmol, 2.2 equiv.) in a methyltert-butyl ether (MTBE)/water mixture at 25° C., up to pH 12 of theaqueous layer. The organic layer is then separated and acidified with31% w/w aq. HCl (17.6 g, 149.643 mmol, 1.2 equiv.) up to pH 1 in theaqueous layer. The aqueous layer is separated and residual water isstripped out of the organic phase by azeotropic distillation (T=54°).Once water is completely removed a white precipitate is formed and theorganic solvent is distilled off (T=54°-55° C., P=900 mbar) until a 40%reduction of the total volume is achieved. The slurry is then cooleddown to 0° C. and filtered.(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa) (46.7 g, 119.175 mmol, 98.1% yield) isobtained as a white powder (HPLC assay: 99.5% w/w).

Method B

(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminebisulfate salt (VIIb) (5.0 g, 11.026 mmol) is dissolved in a hotwater/2-propanol mixture 7:3 vol/vol (55 mL). The solution is then addedwith concentrated hydrochloric acid (6.5 g, 55.521 mmol) and cooled downslowly to 25° C. A white precipitate is formed, the slurry is filteredand the solid washed with water.(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa) (3.9 g, 9.953 mmol, 90.3%% yield) is obtainedas a white powder.

EXAMPLE 13 Synthesis of Cinacalcet hydrochloride (I) from(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa)

A mixture of(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminehydrochloride salt (VIIa) (5.0 g) and palladium catalyst (0.0005-0.01equiv.) in alcoholic solvent or in alcohol/ester mixtures (30-50 mL) ispressurized with 1 bar hydrogen and stirred at +20° C. The mixture isthen filtered through a Celite° pad and concentrated in order to giveCinacalcet hydrochloride (I) which is optionally recrystallized fromether or ester solvents or mixtures thereof (see the following table fordetailed results).

% Cat, Solvent, Time, Conversion, Isolated Catalyst mol/mol v/v hrs %Yield, % PdCl₂ 1.0 EtOAc/MeOH 1:1 10 100.0 92.0 PdCl₂ 1.0 EtOAc/MeOH 1:10.5 100.0 92.5 PdCl₂ 0.6 iPrOH/MeOH 3:1 96 99.8 80.5 PdCl₂ 1.0EtOAc/MeOH 1:1 28 99.9 88.0 Pd/C 0.5 EtOAc/MeOH 1:1 1 99.8 90.0 Pd/C0.15 EtOAc/MeOH 1:1 2 99.9 90.0 Pd/C 0.05 EtOAc/MeOH 1:1 5 99.8 90.0Pd/C 0.05 EtOH 9 99.9 90.0 Pd/C 0.05 MeOH 9 99.9 90.0

EXAMPLE 14 Synthesis ofN-[(1R)-1-(1-naphthyl)ethyl]-3-[3-(trifluoromethyl)phenyl]propan-1-amineHZ salt (Ia) wherein Z=bisulfate (Cinacalcet bisulfate) from(R,E)-N-(1-(naphthalen-1-yl)ethyl)-3-(3-(trifluoromethyl)phenyl)prop-2-en-1-aminebisulfate salt (VIIb)

A mixture of(R,E)-N-(1-(naphthalen-1-yl)-ethyl)-3-(3-(trifluoromethyl)-phenyl)prop-2-en-1-aminebisulfate salt (VIIb) (5.0 g) and 5% palladium on carbon (0.0005 equiv.)in ethyl acetate/methanol 1:1 vol/vol (40 ml) is pressurized with 1 barhydrogen and stirred at +20° C. for 10 hours. The mixture is thenfiltered through a Celite® pad and concentrated in order to giveCinacalcet bisulfate, which is recrystallized from ether or estersolvents or mixtures thereof, affording 84.0% yield.

EXAMPLE 15

Conversion of Cinacalcet bisulfate into Cinacalcet hydrochloride (I)

Cinacalcet bisulfate (1.0 g, 2.200 mmol) is dissolved in a hotwater/2-propanol mixture (12-14 mL). The solution is then cooled down to20° C. and concentrated hydrochloric acid (1.0 g, 8.493 mmol) is added.A white precipitate is formed, the slurry is filtered and the solidwashed with water. Cinacalcet hydrochloride (I) (0.7 g, 1.777 mmol,80.8% yield) is obtained as a white powder. (HPLC assay: 99.5% w/w).

1. A method for preparing Cinacalcet hydrochloride of formula (I)

which comprises the steps of: e) reducing a compound of formula (VII)

wherein Z is chloride or another pharmaceutically acceptable anioniccounterion, to obtain a compound of formula (Ia)

wherein Z is as defined above and, when in a compound of formula (Ia) Zis a pharmaceutically acceptable anionic counterion different fromchloride, f) converting said compound of formula (Ia) to Cinacalcethydrochloride of formula (I).
 2. A method according to claim 1, whereinthe pharmaceutically acceptable anionic counterion different fromchloride is selected from bromide, bisulfate, methanesulfonate,p-toluenesulfonate, phosphate, hydrogenphosphate, oxalate, formate,acetate, citrate, tartrate, succinate, maleate and malonate.
 3. A methodaccording to claim 1, wherein when in the compound of formula (VII) Z ischloride, the compound has formula (VIIa)


4. A method according to claim 3, which further comprises obtaining thecompound of formula (VIIa), with a process which comprises the step of:g) converting a compound of formula (VII)

wherein Z is a pharmaceutically acceptable anionic counterion differentfrom chloride.
 5. A method according to claim 1, wherein in a compoundof formula (VII), Z is different from chloride.
 6. A method according toclaim 4, wherein in the compound of formula (VII) Z is bisulfate, namelyit is a compound of formula (VIIb)


7. A method according to claim 4, which further comprises obtaining acompound of formula (VII) wherein Z is a pharmaceutically acceptableanionic counterion different from chloride, with a process whichcomprises the step of: j) eliminating sulfuric acid from the compound offormula (VIII)

wherein the wavy line represents a bond connected to carbon having R orS configuration, with a strong acid, neutralizing and acidifying with anacid HZ, wherein Z is a pharmaceutically acceptable anionic counteriondifferent from chloride.
 8. A method according to claim 7, wherein thestrong acid is sulfuric or phosphoric acid.
 9. A method according toclaim 7, wherein the acid HZ is H₂SO₄.
 10. A method according to claim7, which further comprises obtaining the compound of formula (VIII),with a process which comprises the steps of k) reducing the compound offormula (V)

to the corresponding benzylic alcohol of formula (Va)

wherein [ ] means that the compound of formula (Va) can be isolated ornot from the reaction mixture, in the presence of a reducing agent or bymean of a catalytic hydrogenation process, and l) converting thecompound of formula (Va) into the sulfate ester of formula (VIII).
 11. Amethod according to claim 10, which further comprises obtaining thecompound of formula (V), with a process which comprises the steps of: a)reacting 3-(trifluoromethyl)acetophenone of formula (II)

with (R)-(1-naphthyl)ethylamine of formula (III) optionally in thehydrochloride form,

in the presence of formaldehyde and hydrochloric acid.
 12. A methodaccording to claim 10, which further comprises obtaining the compound offormula (V), with a process which comprises the steps of: b) reactingthe compound of formula (II)

(i) with a compound of formulaHNR₁R₂, wherein R₁ and R₂ represent, independently, hydrogen or C₁-C₅alkyl, provided that when one of R₁ and R₂ is hydrogen, the other is nothydrogen; or wherein R₁ and R₂ together form a C₄-C₇ alkyl bridge, sothat with the inclusion of the nitrogen atom to which they are linked aheterocycle is formed, wherein one —CH₂— group of the C₄-C₇ alkylbridge, can be replaced by —O—, in the presence of formaldehyde; or (ii)with a N-methyl-N-methylenemethanaminium halide of formula

wherein Hal is a halogen atom, to obtain the compound of formula (IV)

wherein R₁ and R₂ are as defined above; c) alkylating the compound offormula (IV) with an alkylating agent selected from the group ofcompounds of formula: R₃—X, CO(OR₃)₂, SO₂(OR₃)₂, PO(OR₃)₃, CH₃PO(OR₃)₂and (4-NO₂C₆H₄O)PO(OR₃)₂, wherein R₃ is C₁-C₄ alkyl and X is I, Br,OSO₂CF₃ or OSO₂F, to obtain a compound of formula (IVa)

wherein Y═X as defined above, R₃OCO₂, R₃OSO₃, (R₃O)₂PO₂, CH₃PO₂OR₃, or(4-NO₂—C₆H₄O)PO₂OR₃; and d) coupling a compound of formula (IVa) with(R)-(1-naphthyl)ethylamine of formula (III)


13. A method for preparing Cinacalcet intermediate of formula (VIII)

wherein the wavy line represents a bond connected to carbon having R orS configuration, which comprises the steps of: k) reducing the compoundof formula (V)

to the corresponding benzylic alcohol of formula (Va)

wherein [ ] means that the compound of formula (Va) can be isolated ornot from the reaction mixture, in the presence of a reducing agent or bymean of a catalytic hydrogenation process, and l) converting thecompound of formula (Va) in the sulfate ester of formula (VIII).
 14. Amethod for preparing Cinacalcet hydrochloride of formula (I)

which comprises the steps of k) reducing the compound of formula (V)

to the corresponding benzylic alcohol of formula (Va)

wherein [ ] means that the compound of formula (Va) can be isolated ornot from the reaction mixture, in the presence of a reducing agent or bymean of a catalytic hydrogenation process, l) converting the compound offormula (Va) into the sulfate ester of formula (VIII)

wherein the wavy line represents a bond connected to carbon having R orS configuration, j) eliminating sulfuric acid from the compound offormula (VIII) with a strong acid, neutralizing and acidifying with theH₂SO₄ to give the compound of formula (VIIb)

g) converting the compound (VIIb) into the compound (VIIa) and

e) reducing the compound (VIIa) to Cinacalcet hydrochloride of formula(I).
 15. Cinacalcet intermediate having the following formula (VII)

wherein Z is chloride or another pharmaceutically acceptable anioniccounterion.
 16. Cinacalcet intermediate according to claim 15, whereinthe pharmaceutically acceptable anionic counterion is selected fromchloride, bromide, bisulfate, methanesulfonate, p-toluenesulfonate,phosphate, hydrogenphosphate, oxalate, formate, acetate, citrate,tartrate, succinate, maleate and malonate.
 17. Cinacalcet intermediatehaving the following formula (VIIa)


18. Cinacalcet intermediate having the following formula (VIIb)


19. Cinacalcet intermediate having the following formula (VIIc)


20. Cinacalcet intermediate having the following formula (VIId)


21. Cinacalcet intermediate having the following formula (VIIe)


22. Cinacalcet intermediate having the following formula (VIII)

wherein the wavy line represents a bond connected to carbon having R orS configuration.